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The Newby Foundries Group comprises of 4 companies providing our key services.
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t: 0044 (0) 121 556 4451
 

Processes

sand moulds

3D Sand Printing

 

Moulds and cores are created from CAD files and 3D printed in sand.

 

Advantages:

  • Very fast turn around for low quantities (usually 2-3 days) because a pattern is not required.
  • No draft is needed and undercuts are possible.
  • Complex one-piece core assemblies can be produced.
  • Parts can be produced in various sizes and weights.
  • Build dimensions are 750 x 700 x 1500mm.
  • Up to 100kg.
  • A tolerance of CT10-11 is achievable.
  • Parts can be cast in a wide variety of materials.
  • Future modifications are easy.

 

Limitations:

  • Part prices do not decrease as quantities increase.
  • Thin sections of core can be relatively weak.
  • The layered construction of the mould can leave stepping on some surfaces (300-500┬Ám).
  • Production of identical parts in the future will take longer than using a standard pattern.

Rapid turnaround.

Resin Tooling / Airset Moulding

 

Prototype airset moulds and coreboxes can be cut from resin board.

 

Advantages:

  • Cheaper than shell patterns.
  • Not restricted by a plate size.
  • Faster to cut than shell patterns. Approximately 1-2 weeks depending on size and weight.

 

Limitations:

  • Tooling is less durable and less suited to higher volume production.
  • They have the same restrictions as traditional patterns (e.g. draft).
  • A tolerance of CT11 is achievable which is lower than shell.

Repeatable process

sand printer (2)
Sand castings 2

Iron Patterns and Shell Moulds

 

For some applications and quantities a standard iron shell pattern can be optimal.

 

Advantages:

  • They are very durable and can therefore be used for full production if the prototype designs are successful.
  • Parts made from shell have a smoother surface finish than other sand casting techniques
  • A high tolerance of CT9 is achievable.
  • Cores are very strong.
  • Vacuum backed shell moulds enable larger high quality castings to be made (up to 100kg).

 

Limitations:

  • Long lead times are required (3-6 weeks).
  • More expensive than airset tooling.
  • Moulds are restricted by plate size (600 x 400mm)
  • They have the same restrictions as traditional patterns (e.g. draft).

High tolerance prototypes

Hybrid Moulding

 

  • Sometimes it is optimal to use a combination of two manufacturing processes.
  • For example, a part with a simple exterior profile but a complex core (such as a hydraulic valve) may be more cost effective to produce using a shell or airset pattern combined with a 3D sand printed core.

Combine processes for an optimal solution

sand moulds (2)
fettling robot

3D Printed Tooling

 

Newby RapidCast has in-house 3D printing capabilities.

Advantages:

  • Patterns can be produced very quickly, usually overnight.
  • They can then be used in conjunction with the airset or greensand processes.

 

Limitations:

  • This process suited mainly to grey iron prototype castings.
  • Only parts with a low complexity level can be produced.
  • Maximum part size is relatively small (up to 250 x 200 x 200mm) unless patterns are produced in 2 or more sections.
  • Parts have a low tolerance of CT12.

3D printing can also be used to make models of parts for concept modelling, fit & form analysis and machining setup.

Very fast and cost effective prototypes.

NEWBY RAPIDCAST PRODUCE PROTOTYPE CASTINGS USING THE LATEST TECHNOLOGIES SUCH AS SAND PRINTING, SIMULATION SOFTWARE AND 3D SCANNING.

Would you like to discuss a project?
Contact us here today.